Modular frame area floor covering

ABSTRACT

A flooring system including a modular frame surrounding modular floor covering units. Frame members attach easily to one another, providing stability to the flooring system and ease of installation.

RELATED APPLICATION DATA

This application is a continuation-in-part of U.S. application Ser. No.10/381,025, which is a U.S. National Phase application of InternationalApplication No. PCT/US01/29313, filed Sep. 19, 2001, incorporated byreference herein.

FIELD OF INVENTION

The invention generally relates to the field of carpet and floorcovering, specifically to the area of self contained flooring systems.

BACKGROUND OF THE INVENTION

Floor covering has included a vast array of materials such as ceramictile, wood, carpet, carpet tile and other materials. Equally as numeroushave been the methods for installing and securing flooring, eitherpermanently or temporarily, to subfloors. Traditionally, among otherapproaches, flooring systems have used surrounding walls as a method ofcontaining and securing the flooring material. However, this methodprovides very little flexibility to the installer of the flooringsystem. Using existing walls as lateral support for flooring materialsrequires that the installer invest substantial time and labor to fit theflooring materials to the existing subfloor. Accordingly, a need existsfor a method or system that allows floor tiles to be contained andlaterally supported by a means other than the existing walls of thestructure.

SUMMARY OF THE INVENTION

This invention is a self contained kit or a group of components fromwhich a purchaser can assemble an area floor covering. In oneembodiment, a four-sided modular frame surrounds modular units of carpetor carpet tile bounded by the frame, which also provides transition fromthe carpet to the floor on which the assembly lies. Frame members may beattached to the modular units and to one another. The frame members maybe made of plastic, wood, metal, ceramic, marble, or other suitablematerials.

One feature of this invention is a system having components salablethrough retail outlets for producing an area floor covering.

Another feature of this invention is a system and method for containingreplaceable wear surfaces without reliance on interior walls of a roomfor lateral support.

Yet another feature of this invention is an efficient method ofinstalling replaceable wear surfaces in any room with a minimalinvestment of time and labor.

Another feature of this invention is an area floor covering having anexterior frame that is stable and easy to assemble.

An aspect of this invention provides an area floor covering, comprisinga plurality of replaceable wear surfaces having edges, and a pluralityof connectable edge segments adapted to bound the plurality ofreplaceable wear surfaces when connected and comprising a flap havingattachment material for attaching one of the replaceable wear surfaces.

Another aspect of this invention provides a framing system for an areafloor covering, the framing system comprising a plurality of connectableframe segments, each segment comprising: a flap comprising adhesive forattaching a replaceable wear surface; an aperture adapted to receive aconnector; and a connector retainer.

Another aspect of this invention provides an area floor coveringcomprising a plurality of carpet tiles and a frame adapted to bound theplurality of carpet tiles, the frame comprising: at least one connector;at least two edge segments, each segment comprising a flap comprisingadhesive for attaching a replaceable wear surface, and an apertureadapted to receive the connector; and at least one a connector retainer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of an area rug of this invention.

FIG. 2 is a side elevation view of the rug of FIG. 1.

FIG. 3 is a cross-sectional view of a segment and replaceable wearsurface of this invention.

FIG. 4 is a perspective view of a portion of the exterior frame of FIG.1.

FIG. 5 is an end view in cross-section of a segment of FIG. 1.

FIG. 6 is a plan view of the bottom of the connection between twosegments, without a retainer.

FIG. 7 is a perspective view of a collaboration of pieces for forming anarea rug.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an area rug flooring system 10 of this invention. Theflooring system 10 includes an exterior base 12 and multiple replaceablewear surfaces 14. The replaceable wear surfaces 14 maybe carpet tiles orhard surface modules composed of materials such as, but not limited tohardwoods or ceramics.

In one embodiment, exterior frame 12 includes multiple segments 16 sizedto receive replaceable wear surfaces 14. The segments 16 typically arejoined at a 90° angle to form a square or rectangular base 12 around thearea rug 10. Alternatively, segments 16 may be joined at other angles toform various shapes to suit the needs of the layout of the desireddesign. In the embodiment shown, the segments 16 include linear sides 18and corners 20. Corners 20 and linear sides 18 are joined to form arectangular exterior frame 12. However, the exterior frame 12 may becomprised of any number of segments 16 in any number of shapes,including triangular, circular, and any shape in between. Thereplaceable wear surfaces 14 may be assembled in various combinationsand patterns to suit the needs and tastes of the consumer.

FIG. 2 is a side elevation view of the system 10. The exterior frame 12can be constructed of a variety of materials including plastics, wood,rubber, metals, ceramics, marble and other resilient and workablematerials. Extruded plastic or aluminum profiles are particularlydesirable for use as exterior frame 12.

FIG. 3 is a cross-sectional view showing a replaceable wear surface 14disposed within the exterior frame 12. The segment 16 can have athickness equal to or approximately equal to the thickness of thereplaceable wear surface 14. However, segment 16 could also have athickness less than or more than the thickness of replaceable wearsurface 14.

As shown in FIG. 3, frame 12 includes an exterior surface 17, which maybe formed from a hard plastic, and a flap 19, which may be formed from asoft plastic. Exterior surface 17 also includes contact surface 21,which may be formed from soft plastic, which provides non-skidproperties to the frame member. Segments 16 and corners 20 may beco-extruded during manufacture. Upper surface 23 of flap 19 includes anadhesive 25, which adheres to a replaceable wear surface 14. Adhesive 25may be a peel and stick adhesive, or any other adhesive suitable forattaching a replaceable wear surface. Segments 16 are sized tocorrespond to the size of a modular carpet tile, or may be designed inany suitable size or shape.

Segments 16 may be joined in a number of ways including adhesives, snapfittings, sonic welding, splines, nails, screws, or other means ofattachment. In one embodiment, as shown in FIGS. 5 and 6, the segments16 include an aperture on the underside of the segment 16 and spacedfrom an end of the segment 16. The aperture is adapted to receive end 28of a connector 30. A second end 28 of a connector 30 is received in anaperture in a second segment 16. Tensioner 32 extends between ends 28 ofconnector 30 and is received in channel 34 on the underside of thesegment. Retainer 36 having recess 38 snaps in place over connector 30,securing the position of the components. Lip 40 of retainer 36 joinswith ridge 42 of segment 16 and the opposite edge 44 of retainer 36 fitsover protrusion 46 of segment 16 so that retainer 36 locks in place overeach channel 34 of each segment 16. Retainer 36 thus provides torsionalstability to the union of the two segments 16. In this manner, connector30 and retainer 36 join two segments 16.

The components of flooring system 10 may be sold unassembled so that thepurchaser may assemble the exterior base 12 by joining segments 16 andcorners 20 and positioning replaceable wear surfaces 14 within exteriorbase 12 in an arrangement chosen by the purchaser.

The system described above can be marketed and sold as a kit. FIG. 7illustrates various components that may be included in variousquantities. For instance, the system can be contained within acontainer, such as a pasteboard or other box. Alternatively, the systemcan be sold as individual components so that a consumer can select thepieces, such as segments 16, and replaceable wear surfaces 14. Further,the segments may by offered in various thickness, lengths, colors anddesigns. The replaceable wear surfaces 14 may also be offered in varioussizes, colors and designs.

An advantage of this invention is that it provides systems and methodsfor installing free lay replaceable wear surfaces with a minimalinvestment of time and labor.

Another advantage of this invention is that it provides systems andmethods for containing many types of hard and soft replaceable wearsurfaces without the need for lateral support or containment typicallyprovided by interior wall surfaces.

Yet another advantage of this invention is that it provides systems andmethods for a flooring structure where the surface may be easilyreplaced.

Still another advantage of this invention is that modules of thereplaceable wear surface may be assembled in multiple configurations inorder to obtain multiple designs with the same components.

An additional advantage of this invention is that the rug may beinstalled in oddly shaped rooms with a minimal investment of time andlabor.

While various embodiments of this invention have been described above,these descriptions are given for purposes of illustration andexplanation. Variations, changes, modifications and departures from thesystems and methods disclosed above may be adopted without departurefrom the spirit and scope of this invention.

1. An area floor covering, comprising: (a) a plurality of replaceablewear surfaces having edges; and (b) a plurality of connectable edgesegments adapted to bound the plurality of replaceable wear surfaceswhen connected and comprising a flap having attachment material forattaching one of the replaceable wear surfaces.
 2. The area floorcovering of claim 1, wherein the edge segments are each sized tocorrespond to the size of a replaceable wear surface edge.
 3. The areafloor covering of claim 1, wherein the edge segments further comprise atleast two linear side segments and four corner segments.
 4. The areafloor covering of claim 1, wherein the edge segments further comprisecurved segments.
 5. The area floor covering of claim 1, wherein the edgesegments further comprise linear edge segments.
 6. The area floorcovering of claim 1, wherein the connectable edge segments furthercomprise an aperture adapted to receive a connector, and a connectorretainer.
 7. The area floor covering of claim 1, further comprising atleast one connector.
 8. The area floor covering of claim 7, wherein theconnector further comprises a tensioner adapted to provide torsionalstability to the union of two segments.
 9. The area floor covering ofclaim 1, wherein the replaceable wear surfaces comprise carpet tile. 10.The area floor covering of claim 1, wherein the attachment materialcomprises adhesive.
 11. A framing system for an area floor covering, theframing system comprising a plurality of connectable frame segments,each segment comprising (a) a flap comprising adhesive for attaching areplaceable wear surface; (b) an aperture adapted to receive aconnector; and (c) a connector retainer.
 12. The framing system of claim11, further comprising replaceable wear surfaces.
 13. The framing systemof claim 12, wherein the frame segments are each sized to correspond tothe size of a replaceable wear surface.
 14. The framing system of claim11, wherein the frame segments further comprise at least two linear sidesegments and four corner segments.
 15. The framing system of claim 11,wherein the frame segments further comprise curved segments.
 16. Theframing system of claim 11, wherein the frame segments further compriselinear segments.
 17. The framing system of claim 11, further comprisingat least one connector.
 18. The framing system of claim 17, wherein theconnector further comprises a tensioner adapted to provide torsionalstability to the union of two segments.
 19. The framing system of claim11, wherein the framing segments are adapted to frame a plurality ofcarpet tiles.
 20. The framing system of claim 11, further comprising atleast one carpet tile and at least one connector.
 21. An area floorcovering comprising a plurality of carpet tiles and a frame adapted tobound the plurality of carpet tiles, the frame comprising: (a) at leastone connector; and (b) at least two edge segments, each segmentcomprising (i) a flap comprising adhesive for attaching a replaceablewear surface; and (ii) an aperture adapted to receive the connector; and(c) at least one a connector retainer.